NOT AND ACCEPTANCE STANDARDS FOR THE

HEMISPHERICAL HEADS OF H«P. HEATERS

!• GENERAL:

Ttw Standard details the non-destructive testing coverage,

tKe surface preparation, the non-destructive procedures
and techniques and standard of acceptance that shall be
applied during the manufacture of hemispherical heads.
2. NON-DESTRUCTIVE TESTING COVERAGE:

2» 1 Plate material adjacent to weld preparations

Plate material intended for hemispherical heads shall be
ultrasonically tested prior to welding in the areas
adjacent to the weld preparations for the distances given
below:
(1) Manhole facing weld preparations - 1.75T +25*ram
(2) Feed branch weld preparations - T +25 mm
(3) Hemisphere to tubeplate weld preparation - 1.75T +25 m
*

*T m thickness of hemispherical head plate material mm.

2*2 Weld Preparations
All weld preparations on hemispherical heads, feed branch
and manhole forgings shall be subjected to visual and
magnetic particle inspection before welding*
2»3 Back chipping
Where back chipping is employed during the welding of the
manhole forging to hemisphere weld, the root of the
excavation shall be proved by magnetic particle inspection
before proceeding with final welding.
2»4 Feed branch and manhole facing welds
On completion of welding and stress relieving the welds
shall be subjected to visual, magnetic particle and
ultrasonic examination.
 2. NON-DESTRUCTIVE TESTING COVERAGE: (contd.)

2.5 Attachment welds

On completion of welding and stress relieving the welds

shall be subjected to visual and magnetic particle
examination.
2 6
• Feed branch weld preparations - site welds
After profiling and before despatch the flni'sh«d weld
preparations shall be examined by visual and magnetic
particle inspection.
3. SURFACE PREPARATION!

All surfaces that are to be tested shall be free from scale

Spatter dirt^paiht and shall have a flatness and finish
such that good acoustic coupling can be achieved during
ultrasonic testing* .. ...
Weld preparations, the surfaces of welded joints and
adjacent material shall have a finish equal to or better
than 6.3 jmm Ra (N9). This shall be checked by comparison
with a Rubert El'ectroformed Roughness Comparison Specimen
Number 128.
On branch welde the reinforcement shall be ground flat,
whilst maintaining the required taper/ so that ultrasonic
tests may be carried out from this surface where dimension-
ally possible.
4, NON-DESTRUCTIVE TESTING PROCEDURESi

4.1 Visual Inspection shall be carried, out at the appropriate

stage of manufacture f9r surface .defects requiring recti-
fication and to ensure that the surfaces comply with the
requirements of clause* 3.
*•2 Magnetic particle inspectign^
Magnetic particle inspection shall be carried out uylng tha
current flow technique in accordance with the requirements
of B.S.6O7Z* Halfwave rectified A.C. shall be used unless
otherwise agreed. A Bertholci Magnetic Penetremeter used
on a setting of 2, or an equivalent instrument shall bo
used to prove the effectiveness of the magnetising field
strength*
Black magnetic flaw detection ink shall be used in conjunc-
tion with a suitable white crack detection background paint. '
The magnetic ink shall conform to B.S. 4069. Water based
inks shall not be used.
4. NON-DESTRUCTIVE TESTING PROCEDUREt (contd.)
The prod;;technique shall be applied in such a manner that
all longitudinal and transverse defects are detected*
The prod spacing shall riot exceed 200 mm.
Note* The sustained current method shall be used to enaur
an adequate build-up Of magnetic particles. Each
section magnetised shall be examined for defects
before proceeding to the next*
Any evidence of prod contact arcing shall be removed by
grinding after completion of this inspection and all grou
areas examined shall be subsequently re-examined using
a permanent or electromagnet technique to B.S. 6072..
4.3 Ultrasonic inspection
4.3.1 Operators
Ultrasonic testing shall be carried out only by approved
operator*. Bach cub-contractor shall submit names of the
operators he intends to use, giving details of the approv-
als obtained, to BHEL, Bhopal.
4.3.2 Equipment
a) Types
The equipment and probes shall conform to B.S. 3923
part 1.
The probes and equipment shall be of the same manufactu
b) Calibration
The equipment shall be calibrated in accordance with
B.S. 3923 Part 1.
The time base shall be re-calibrated at Intervals durin
the examination and with each change of probe.
The beam angle and probe index (where applicable) shall
be checked at regular intervals.
Suppression shall not be used.
c) Probes
These shall be selected from the following}
2 - 2>j MHz 45°single crystal shear wave probes.
4 - 5 MHz 10 - 15 mm diameter combined double crystal
near surface compression wave probe.
4. NON-DESTRUCTIVE TESTING PROCEDUREJ (Contd.)

4.3.2
(contd.)4 - 5 MHz 24 mm diameter/10 mm diameter single crystal
compression wave probe*
4 - 5 MHz 45°twin crystal miniature shear wave probes.
The measured frequency of th« test probe shall be within
the range of 1.5.to 3 MHz or 3.5 - 5.5 MHz depending on
the frequency specified in clause 4.3.4 A suitable method
of measurement is described in B.S. 3923 part 3.
e) Probe size,
Bach dimension of the probe face shall not exceed 25 mm.
The total crystal area shall exceed 50 mm «
f) Sensitivity
(1) Compress ion wave probes
With the first back wall echo" from the 25 mm dimension
of the A2 test block in B»s. 2704 set to full screen
height, there shall be at least 40 dB of gain available I
on the calibrated gain control of the flaw detector. I
(2) Shear wave probes
With the first echo from the 100 mm radius of the A2
test block in B»3»\ 2704 set to full screen height,
there shall be at least 40 dB of gain available on the
calibrated gain control of the flaw detector.

g) Resolution
The 2-2 /2 MHz probes shall be capable of clearly
resolving the 5 mm step in the resolution test blodk
in B,s« 3923t Part 3, and the 4 - 5 MHz probes in the
3 mm step.
h) Test Blocks
The following test blocks shall be provided.
1) Compression Wave test
For compression wave testing, the test block shall
contain,3 mm diameter flat bottomed holes, drilled from
under face at varying depths to provide artificial,
defects upto the maximum thickness of weld.
(Pull screen height echo from the hole situated at
maximum testing distance shall be the reference level).
4. NON-DESTRUCTIVE TESTING; PROCEDURE f (Contd...)

4.3*2 H) Test Blocks i (Cbntd..)

2) Shear wave test
A test block shall be provided containing 3 mm diameter
holes drilled through the block from the side face at
varying depths from the upper (test) face upto the
maximum thickness of the weld.
(Pull screen height echo from the hole at maximum
testing distance shall be the reference level)*
NOTE: Alternatively, DCS scales for compression and/or
shear wave probes may also be used instead of •
having test blocks with drilled holes*

4*3.3 Techniques
4.3.3.1 Plate material
The weld preparation areas of the plate material as called
for in clause 2.1 shall be ultrasonically examined in
accordance with B*S.4336 part 1A technique 1.
NOTE* Any defects that would interfere with the shear wave
examination of the welds shall be referred to BHEL
Bhopal.
4.3.3.2 Manhole facing weld
a) (general
The position of the centre line of the manhoie facing
weld shall be Identified and marked on the inside and
outside surfaces of the weld, before commencement of
ultrasonic Inspection.
b) Scanning
The limits of the scanning zones shall be determined by
the dimensions of the weld and shall be established from
the relevant drawing*
The first 25 mm of weld depth for compression waves and
60 mm of depth for shear waves shall be scanned using
twin probes*
Scanning Operations shall be as follows<
4« NOM-DESTRUCTIVE TESTING PROCEDURE * (Contd.*)

4.3.3*2 Manhole facing weld * (Contd*.*)

1) Scanning of the weld from the outer surfaces of the
head using the 4*5 MHZ combined double near surface
compression wave probe. .
2) scanning of the weld from the outer surface of the
head using the 4 - 5 MHS 10 mm diameter single
compression wave probe.
3)*Scanning of the full weld section from the outer
surface of the head using the 2-2V2 MHZ 45 single
. shear wave.
4)*Scanning of the near surface region of the weld from
the outer surface of the head using the 4 - 5 MHz
45° twin miniature shear wave probes.
5) Circumferential scanning of the weld on the outer
surface, in line with the weld axis using the 4 - 5
MHz 45° twin miniature shear wave probes. This shall
be carried out in two opposite directions.
NOTE: Because of the angle of ; the weld preparation and
the curvature of the head the width of the scanning
limits is critical and should be established from
the drawing.
6) * Scanning of the root region of the weld from the
inner surface of the head using the 4 - 5 MHz 45°
twin miniature shear wave probe.
7) Circumferential scanning of the root region of the
weld from ,the inner surface of the head in line
with weld axis using the 4 - 5 MHz twin minature
shear wave probe. This shall be carried out in two
opposite directions.
* These tests shall be carried out along lines at right
angles to the weld axis over the appropriate scanning
zone. The lateral displacement between traverses
shall be such as to give complete coverage of the
weld*
c) Scanning sensitivity
Scanning sensitivity shall be kept 6 dB above the
reference level*
 4. NON-DESTRUCTIVE TESTING PROCEDURES * (Oontd. . . )

4.3.3.3 Branch welds

a) Scanning
The limits of the scanning zones shall be determined
by the dimensions of the weld and the accessibility.
Scanning operations shall be as follows *
1) Scanning of the weld and adjacent plate material from
the inner surface of the head using the 4 - 5 - MHz
24 mm/10 mmdiameter single compression wave probe.
2) Scanning of the weld from the bore surface using 4 - !
MHz 10 mm diameter single and 10-15 mm diameter
combined double near surface compression wave probe.
3) Scanning of the weld from the flat ground surface of
the reinforcement usiOg the 4 - 5 MHz 10-15 mm
diameter near surface combined double compression
wave probe.
4)*Scanning of the weld from the outer surface of the
branch using the 4 - 5 MHz 45 single miniature shear
wave probes over the full skip distance.
5)*Scanning along the flat ground surface of the weld
re-inforcement at right angles to the weld axis using
the 4 - 5 MHz 45° twin miniature shear wave probes.
6) Circumferential scanning on the surface of the weld
reinforcement in line with the weld axis using the
4 - 5 MHz 45 twin miniature shear wave probes this
shall be carried out in two opposite directions.
7)*Scanning of the weld from the bore in two opposite
directions* i.e. from the branch side and the head
side, .using 4 - 5 MHz 45° twin miniature shear wave
probe.
These tests shall be carried out along lines at right
angles to the weld axis over the appropriate scanning
zone. The displacement between traverses shall be
such as to give complete lateral coverage of the
weld.

4»3«4 Evaluation of indications

All indications which produce a response greater than
20% of the reference level shall be considered relevent
and shall be investigated further, to determine their
length, nature, size etc., in terms of the Acceptance
Standard - Clause 5*
5* ACCEPTANCE STANDARD!

All defects exceeding the acceptance limits specified in

B.S.5500,. Table 5.7 shall be rejected*
6. DOCUMENTATION*

A complete set of records on each weld examined shall be

compiled and retained. There shall include:
(1) Details of MUP.I. as in B.S..607Z.
(2) Details of ultrasonic technique as in clause 4.3.

In the case of a sub-contractor copies of these records

shall be submitted to.BHEL, Bhopal on completion of an
acceptance weld.